Floor covering



P. R. ALLEN FLOOR COVERING July 30, 1935.

Filed Dec. 11, 1934 //\1 VENTOR. w w BY jb fldakg T ATTORNEY Patented July 30, 1935 UNITED STATES FLOOR COVERING Philip R. Allen, Walpole, Mass, assignor to Bird & Son, Inc., East Walpole, Mass., a corporation of Massachusetts Application December 11, 1934, Serial No. 756,991

Claims.

This invention relates to a hard-surfaced flexible non-slip fioor covering and has particularly to do with a floor covering comprising a waterproofed backing fabric having thereon an 'in- 5 dented tread layer of thermo-plastic material in which tread layer there is incorporated and embedded in the surface portion only, a quantity of after-applied finely divided mineral matter. This mineral matter serves a dual purpose in the finished floor covering in that it enables the tread surface when cold to resist shattering and breakage and when warm to prevent any tendency of the thermo-plastic layer to pick up or become tacky. Further, regardless of temperature conditions, the said mineral matter at all times provides a non-slip surface which sharply distinguishes it from ordinary thermo-plastic tread surfaces. Though it might be thought that the said mineral matter, since it is applied to the upper portion only of such plastic material, would soon tend to become loosened and disappear, the fact is that due to the unctuous and softer character of the thermo-plastic material it tends to well up about the particles of mineral matter. Thus, the mineral matter though remaining effecotive for non-slip purposes, is, in result, protected by the plastic material and continues its effectiveness until the plastic layer is worn down substantially to the backing.

In the manufacture of this floor covering, there is first made a sheet of the base material, either woven or felted, but preferably of rag felt saturated with asphalt, though any sort of a fabric or woven sheet may be used, but these generally lack the smoothness and the rigidity of a felt sheet. Likewise, a pitch may be substituted for the asphalt saturant, though the latter is preferable. Following the saturating, the back of the base sheet or backing is preferably coated by paint, wax, or some suitable hardening plastic as is usual with felt base floor coverings or linoleum. The opposite or top face of the asphalt saturated backing then has applied thereto a thermoplastic tread layer, preferably of asphalt (from 175-240 F. melting point) with or without a mineral fillerincorporated therein, in a layer of desired thickness usually, (l20"-025", the thickness of which is controlled by pouring the thermo-plastic at a temperature of say 400 F. upon the surface of the base and then at once passing the sheet through a pair of plain cylindrical internally-heated rolls (the top roll preferably not revolving) with the opening of the rolls such as to allow the desired thickness of plastic to be placed upon the sheet in an even layer, the

application being preferably 1 to 2 lbs. of coating per square yard. Then, while the asphalt surface layer is still hot, there is deposited on the surface thereof a layer of finely divided mineral material (preferably fine crushed slate or slate flour of 200 mesh, though slate flour as fine as 100 mesh will answer) in an amount equal to about a twentieth of the previously applied asphaltic coating. In the commercial practice of the invention .05 to .15 lb. (preferably .1 lb.) of 10 mineral matter is applied to each square yard of the sheet material. This mineral surfacing is spread upon the upper surface of the moving sheet which is then passed through a pair of rolls to press the mineral material into the asphaltic coating, the bottom one plain and the upper of which rolls has any suitable design thereon so that before the asphaltic layer has cooled and hardened to depress and raise portions of the surface of the plastic to give a better non-slip surface and also, for appearance sake, to form designs because of the difierence in relief. These rolls are not internally heated, and in fact, to work satisfactorily the upper or indenting roll must be at a temperature lower than the melting point of the asphaltic coating. By thus employing a relatively cool upper roll no sort of external treatment or application is required to prevent it from sticking to the plastic because the interposed layer of mineral material which the upper roll serves to force into the surface portion of the thermoplastic prevents such plastic material from sticking to the upper or indenting roll.

The drawing Figures 1 and la (the latter being a continuation of the first figure) illustrate diagrammatically the steps in the commercial practice oi the invention.

Referring to the drawing, the sheet of dry felt is led from the roll l, thence through a saturator i where it is saturated with asphalt from which saturator 2 the sheet is carried to a backing paint applying device 3 where the backing paint is applied to the bottom surface of the sheet. After the backing paint is applied, the sheet receives at Q upon its upper surface a coating of asphalt or the like, and is then at once passed through a pair of cylindrical heated rolls 5 from which it goes, while still hot, under the slate depositing device t which sifts a layer on to the upper surface of the moving sheet. The material is then slightly cooled by being passed about cooling drum 5 from which it is taken by a pair of pull rolls 0 which present the material to the rolls t, the upper of which, but while the asphalt is still in a soft condition, indents and forms a design in the upper surface thereof. From the rolls 9 the material is ledthrough a cooling looper l0 which further cools the material which is finally wound up at H in its finished condition. Having described my invention what I claim is:'-

l. A hard-surfaced flexible non-slip floor-covering material comprising a base layer of fabric saturated with a hardened water-proofing material, said base layer having'upon its upper surface a tread layer of thermo-plastic asphaltic material solid at atmospheric temperatures, said tread layer being indented to provide a tread surface and having embedded in the upper portion of the exposed surface thereof a substantial portion of finely divided mineral matter passing mesh.

'2. A hard-surfaced flexible non-slip floor covering material comprising a base layer of fabric saturated with a hardened water-proofing material, said base layer having upon its bottom face an additional backing layer of water-proof material and upon its upper surface a tread layer of thermo-plastic asphaltic' material solid at atmospheric temperatures, said tread layer being indented to provide a tread surface and having embedded in the upper portion of the exposed surface thereof a substantial portion of finely divided mineral matter passing 100 mesh.

3. A hard-surfaced flexible non-slip floor covering material comprising a base layer of ragfelt fabric saturated with a hardened asphaltic water-proofing material, said base layer having upon its upper surface a tread layer of thermoplastic asphaltic material solid at atmospheric temperatures, said tread layer being indented to provide a tread surface and having embedded in the upper portion of the exposed surface thereof a substantial portion of finely divided mineral matter passing 100 mesh.

4. A hard-surfaced flexible non-slip floor covering'material comprising a base layer of fabric saturated with a hardened asphaltic water-proofing material, said base layer having upon its bottom face an additional backing layer of waterproof paint material and upon its upper surface a tread layer of thermo-plastic asphaltic material solid at atmospheric temperatures, said tread layer being indented to provide a tread surface and having embedded in the upper portion of the exposed surface thereof a substantial portion of finely divided mineral matter passing 100 mesh.

5. A hard-surfaced flexible non-slip floor covering material comprising a base layer of fabric surface thereof a substantial portion of finely divided slate passing 100 mesh.

' PHILIP R. ALLEN 

